External rotor motor with integrated bearing housing and box for control electronics

ABSTRACT

A fan has an electronically commutated external-rotor motor serving to drive it. The motor has an internal stator ( 20 ) having a stator lamination stack ( 64 ) and a winding arrangement ( 66; 164, 166, 168, 170 ) associated with said stack. The internal stator has a central opening ( 149 ) for journaling a shaft ( 42 ). The fan further has a permanent-magnet rotor ( 28 ) separated from the internal stator ( 20 ) by a magnetically effective air gap ( 99 ), which rotor is equipped on its outer side with fan blades ( 32 ) and comprises a shaft ( 42 ) journalled in the central opening ( 149 ) of the internal stator ( 20 ). Also provided is a plastic coating ( 56, 58 ) that extends into the central opening ( 149 ) of the internal stator ( 20 ) and forms there a bearing tube for the reception of bearing elements ( 48, 50 ) for journaling the shaft ( 42 ); also a wall element ( 62 ), implemented integrally with said plastic coating ( 56, 58 ), for a cavity ( 108 ) for the reception of electrical components ( 112 ) of the motor, which wall element ( 62 ) is provided on the side of the stator lamination stack ( 64 ) facing away from the rotor ( 28 ); and a fan housing ( 24 ) which is connected integrally, by means of connecting elements ( 134, 136 ), to the wall element ( 62 ) of the cavity ( 108 ) and which forms, together with the rotor ( 28 ), an air passage conduit ( 142 ) into which the fan blades ( 32 ) project.

The invention relates to an external-rotor motor, and it relates to a fan having an external-rotor motor serving to drive it.

Such fans are used in large numbers, chiefly for cooling electronic devices, for example computers, servers, high-performance television sets, etc. Great importance is attached to an inexpensive but still robust design that, in particular, can also be expected to offer a long service life for the fan.

It is therefore an object of the invention to make available a novel external-rotor motor and a fan of the kind recited above.

According to the invention, this object is achieved by the subject matter of Claim 1. A fan of this kind has a very simple design and can therefore be manufactured inexpensively. When the motor is manufactured, the bearing tube of the motor and the external housing of the fan can be manufactured in one working step. Improved motor efficiency is also obtained, since the lamination cross section of the stator can be enlarged without enlarging the dimensions of the fan, enabling a higher fan rotation speed and thus higher fan output.

This also makes possible a more compact design and allows selection from a larger number of rotor magnets, and it is more easily possible to optimize costs.

The invention thus makes it possible to manufacture a better product at reduced cost.

Further details and advantageous refinements of the invention are evident from the exemplifying embodiments, in no way to be understood as a limitation of the invention, that are described below and depicted in the drawings, and from the dependent claims. In the drawings:

FIG. 1 is a longitudinal section through the basic framework of an external-rotor motor including its internal stator and its fan housing;

FIG. 2 is a perspective view of the basic structure of FIG. 1, viewed approximately in the direction of arrow II of FIG. 1;

FIG. 3 is a depiction analogous to FIG. 1, but in which a circuit board on which electrical components of the motor are located is installed;

FIG. 4 is an enlarged depiction of detail IV of FIG. 3;

FIG. 5 is a plan view looking in the direction of arrow V of FIG. 3;

FIG. 6 is a section looking in the direction of line VI-VI of FIG. 5;

FIG. 7 is a depiction analogous to FIG. 3 but in the closed state;

FIG. 8 is a variant of FIG. 7;

FIG. 9 is a depiction analogous to FIG. 7, in the context of assembly of the permanent-magnet rotor;

FIG. 10 is a sectioned depiction of the motor of FIG. 9 in the assembled state, viewed along line X-X of FIG. 12;

FIG. 11 is an enlargement of detail XI of FIG. 10, in which an assembly tool is additionally indicated;

FIG. 12 is a plan view looking along arrow XII of FIG. 10;

FIG. 13 shows identical salient poles 140, 142, 144, 146 and a magnetic yoke 148 inside which bearing tube 56 (FIG. 1) is located when the fan is complete.

FIG. 14 is a sectioned depiction of a contact pin that serves for connecting the internal stator to the circuit board.

FIG. 1 is a longitudinal section through internal stator 20 of an external-rotor motor 22 depicted in FIG. 10 and its fan housing 24, in which a fan wheel 26 (FIG. 9) rotates during operation. The wheel is constituted by an external rotor 28 on whose outer circumference 30 fan blades 32 are implemented. The rotation direction of external rotor 28 is labeled 34 in FIG. 12.

Each fan blade 32 preferably has on its outer periphery an enlargement 36, in order to improve the efficiency of fan wheel 26.

As FIG. 9 shows, external rotor 28 has a cup-shaped magnetic yoke 38 made of soft iron, and the latter is connected at its center to a hub 40 in which a shaft 42 is secured in the manner depicted. Hub 40 has openings 44 that are utilized upon assembly of the fan, and whose function will be further explained below.

Shaft 42 has two rolling bearings to journal it, namely a first rolling bearing 48 on the side of shaft 42 facing toward rotor 28, and a second rolling bearing 50 on the side of shaft 42 facing away from rotor 28. Located between the outer rings of rolling bearings 48, 50 is a spacing member 52 (see FIG. 9). This is guided on shaft 42.

A bearing tube 56, which is depicted in FIG. 1, serves to receive rolling bearings 48, 50 and spacing member 52. Said tube has, on its inner circumference, longitudinal ribs 58 whose radially inner ends define a circular enveloping curve. The outer rings of the two bearings 48, 50 are guided in ribs 58.

Bearing tube 56 transitions to the left into a collar 60 (see FIG. 1). It transitions further into a partly insulating casing 62 of internal stator 20, whose stator lamination stack, packeted in the usual manner, is labeled 64, and whose winding arrangement is labeled 66.

Provided in this casing 62 as a continuation of bearing tube 56 is a dimple-like recess 68 whose bottom 70 closes off bearing tube 56 in fluid-tight fashion at this location.

As FIG. 10 shows, bottom 70 forms an axial tolerance region for free end 74 (FIG. 9) of shaft 42, i.e. free end 74 does not abut against bottom 70. A snap ring 76 is provided in the region of free end 74 in a groove of shaft 42, and provided between said snap ring 76 and the inner ring of rolling bearing 50 is a compression spring 78 that clamps the inner rings of rolling bearings 48, 50 against one another, since a projection 80 (FIG. 11) of hub 40, which latter is fixedly connected to shaft 42, abuts against the inner ring of rolling bearing 48, while spring 78 pushes the inner ring of rolling bearing 50 to the left in FIG. 9, so that the inner rings of rolling bearings 48, 50 are clamped against one another.

As FIG. 10 shows, the outer ring of rolling bearing 50 abuts against a shoulder 82 (FIG. 1) of bearing tube 56, and is fastened in that position. The inner ring of rolling bearing 48 is arranged slidably (movable bearing) on shaft 42, so that the latter is pressed to the right in FIG. 10. The two rolling bearings 48, 50 can thereby form both a radial and an axial bearing for external rotor 28.

As FIG. 9 shows, the two rolling bearings 48, 50 are pressed in the direction of an arrow 86 into longitudinal ribs 58 of bearing tube 56. This occurs with the aid of pins 92 that are passed through openings 44 of hub 40. FIG. 11 shows only one of said pins 92, which abut during assembly, with their right (in FIG. 11) ends 94, against a securing member 96 and press it against the outer ring of rolling bearing 48, the outer ring of rolling bearing 50 also being displaced by spacing member 52 (FIG. 9) to the right and being brought into abutment against shoulder 82 of bearing tube 56. In this manner, the outer rings of both rolling bearings 48, 50 are fastened in bearing tube 56.

Securing member 96 is fastened in collar 60, in the position that is attained, by the fact that it cuts with its sharp frustoconical edge 98 (FIG. 11) into inner side 100 of collar 60 and therefore can no longer be displaced to the left in FIG. 11. The result is that secure and zero-clearance assembly of rolling bearings 48, 50 in bearing tube 56 is achieved, and securing member 96 produces a hooking effect and tilt prevention for rolling bearings 48 and 50.

As FIG. 10 shows, a magnetically effective air gap 99 is located between internal rotor 20 and magnet 37 of rotor 28.

Internal stator 20 is completely encased with a plastic 62 in an injection molding operation. The following, inter alia, are suitable as plastics:

polyamides, e.g. Ultramid® A3X2G5 or polyamide 66

PBT, e.g. Technyl (PBT-G20FR).

These plastics can be reinforced with fibers, e.g. with approximately 20% to approximately 25% glass fillers. These substances can be welded, for example by ultrasonic welding or laser welding. Adhesive connections, seals, or sealing elements are alternatively possible, for example in the form of two-component plastic parts.

As shown, for example, by FIGS. 1 and 3, stator lamination stack 64 has a slot insulator 104 which forms a coil former into which is wound stator winding arrangement 66, whose shape and construction depend on the use of the motor, and which is therefore depicted only schematically.

As FIG. 4 shows, contact pins 106, which project to the right in FIG. 4, are secured in this slot insulator 104. (FIG. 4 shows only one of these contact pins.) One end of a wire 154 of stator winding arrangement 66 can be electrically and mechanically secured to these contact pins 106. In this exemplifying embodiment, a total of four such pins 106 are provided on internal stator 20.

In FIG. 1 and following, pins 106 project into a cavity 108 whose side wall is labeled 109 and in which is located (as shown in FIG. 3) a circuit board 110 on which electrical components 112 for motor 20 are arranged. As FIG. 5 shows, litz wire strands 114 of a connector cable 116 are attached to circuit board 110. Pins 106 are also soldered onto conductor paths of circuit board 110 by solder connections 118 (see FIG. 4). Circuit board 110 is held by spacing members 120 (FIG. 4) at a distance from plastic casing 62, which latter also forms the bottom and side wall 109 of cavity 108.

After being fitted with circuit board 110 and after litz wire strands 114 are attached (FIG. 5), cavity 108 is closed off with a cover 126. The latter can be, for example, welded with ultrasound to side wall 109 at weld joins 128, or with an adhesive bond.

It is particularly advantageous here that circuit board 110 having electrical components 112 is arranged in a cavity 108, so that components 112 are not overmolded with plastic; this might cause components 112 to be torn away from circuit board 110 by the change in volume as the encapsulating material hardens. This risk does not exist here. It is also not precluded in some cases, however, to overmold components 112 with plastic or provide them with a protective lacquer.

Instead of a cover 126, a closure cap 127 can also be used, as depicted by way of example in FIG. 8. Closure cap 127 can be secured, for example, by welding or adhesive bonding.

As FIG. 2 shows, wall 109 of cavity 108 is connected via three simple spokes 134 and one channel-shaped spoke 136 to fan housing 24, which forms an air passthrough aperture 142 similar to a Venturi conduit. Spoke 136 serves for guidance of cable 116 (see FIG. 5). Cable 116 is sealed by means of a rubber seal (not visible).

Fan housing 24 is thus implemented integrally with a part of the wall of cavity 108 by means of spokes 134, 136, and integrally with the casing of internal stator 20, so that all these parts can be manufactured in a single working step; this simplifies and speeds up production and moreover reduces costs. Since the assembly of rotor 28 is also greatly simplified, the result is an inexpensive product with outstanding properties and a long service life.

FIG. 9 depicts, at 37, the permanent magnet of rotor 28 which is secured in magnetic yoke 38. Its magnetization can be implemented with two poles, four poles, six poles, etc.

FIG. 10 shows how blades 32 project into Venturi conduit 142.

FIG. 13 is a perspective depiction of a completely wound internal stator 20 that serves, so to speak, as a precursor product in the manufacture of a motor or fan. Its stator lamination stack 64 has, in this example, four identical salient poles 140, 142, 144, 146 and a magnetic yoke 148 having a central opening 149 in which, when the fan is complete, is located bearing tube 56 (FIG. 1) with its longitudinal ribs 158.

In this exemplifying embodiment, poles 140 to 146 have different outside diameters on their side facing toward air gap 99 (FIG. 10). In this state, a larger-diameter portion 150 is not yet covered with plastic. A smaller-diameter portion 152 is covered here with insulation made up of two mounted-on half-shells 174, 176. There are various possibilities, known from the existing art, for this covering of the internal stator: for example, as depicted, the use of the two half-shells 174, 176, or overmolding with insulating material, or the use of a special insulating paper. Contact pins 106, which are depicted e.g. in FIGS. 1 to 5, are also attached on upper half-shell 176. FIG. 14 shows how a winding wire 154 is secured to pin 106. For this, the latter is secured in a projection 162 of half-shell 176, and that projection also serves as a spacing member for circuit board 110 (see FIG. 3 or 4).

Located on stator poles 140 to 146 in this example are concentrated windings 164, 166, 168, 170 whose terminals are connected in the usual manner to contact pins 106. The use of a distributed winding and a corresponding lamination stack would of course also be possible.

As shown, for example, by FIG. 1, the wound internal stator 20 is overmolded on all sides with a plastic 62, i.e. including at portions 150 of stator lamination stack 64, only a thin insulation layer (for example, 0.4 mm thick) being produced there.

As FIG. 1 shows, upon overmolding the cavities of internal stator 20 are filled up, bearing tube 56, 58 with its collar 60 is produced, also wall 109 of cavity 108 and spokes 134, 136, and lastly also fan housing 24, so that a fan is obtained, so to speak, in a “single shot.”

After further assembly (circuit board 110, connector cable 116 (FIG. 5)), etc., external rotor 28 is installed as depicted in FIG. 9 and also described there, and lastly an identification plate is attached, etc.

The number of stator and rotor poles, the shape thereof, etc. are of course a function of the desired properties of the motor, as is known to one skilled in the art of electrical engineering. In some cases, for example, stator lamination stack 64 on the air-gap side can be covered with plastic not at all or only over a smaller area, or a very thin plastic layer is used.

Many further variants and modifications are possible, within the scope of the present invention. 

1. A fan having an electronically commutated external-rotor motor serving to drive it, which motor comprises: an internal stator (20) having a stator lamination stack (64) and a winding arrangement (66; 164, 166, 168, 170) associated with said stack, which internal stator comprises a central opening (149) for journaling a shaft (42); a permanent-magnet rotor (28) separated from the internal stator (20) by a magnetically effective air gap (99), which rotor is equipped on its outer side with fan blades (32) and comprises a shaft (42) journalled in the central opening (149) of the internal stator (20); a plastic coating (56, 58) that extends into the central opening (149) of the internal stator (20) and forms there a bearing tube for the reception of bearing elements (48, 50) for journaling the shaft (42); a wall element (62), implemented integrally with the plastic coating (56, 58) of the central opening (149), for a cavity (108) for the reception of electrical components (112) of the motor, which wall element (62) is provided on the side of the stator lamination stack (64) facing away from the rotor (28); and a fan housing (24) which is connected integrally, by means of connecting elements (134, 136), to the wall element (62) of the cavity (108), and which forms, together with the rotor (28), an air passage conduit (142) into which the fan blades (32) project.
 2. The fan according to claim 1, wherein the plastic coating (56, 58) of the central opening (149) is implemented, at least where it serves for the reception of bearing elements (48, 50) for the shaft (42), approximately as a bearing tube.
 3. The fan according to claim 2, wherein the bearing tube is equipped on its inner side with longitudinal ribs (58).
 4. The fan according to claim 3, wherein an enveloping curve defined by the inner ends of the longitudinal ribs (58) has at least in part a circular cross section.
 5. The fan according to one of the preceding claims, wherein the bearing tube comprises a closed end (70) on its side facing away from the rotor (28).
 6. The fan according to one of the preceding claims, wherein the bearing tube (56, 58) is equipped on its side facing toward the rotor (28) with a collar (60) in which is secured a holding member (96) that retains a bearing element (48) in the bearing tube (56, 58).
 7. The fan according to claim 6, wherein the holding member (96) comprises an edge (98) that points toward the rotor (28) and is in engagement with the collar (60) of the bearing tube (56, 58).
 8. The fan according to claim 6 or 7, wherein two rolling bearings (48, 50) are arranged at a distance from one another in the bearing tube (56, 58) as bearing elements, namely a first rolling bearing (48) on the side facing toward the rotor (28), and a second rolling bearing (50) on the side facing away from the rotor (28), in the case of which latter an outer ring is braced with an end face on a shoulder (92) provided in the bearing tube (56, 58), and said outer ring is braced with its other side, via a spacing member (52), against an oppositely located shoulder of the outer ring of the first rolling bearing (48), which outer ring is in turn retained in the bearing tube by the holding member (96).
 9. The fan according to one of the preceding claims, wherein the rotor (28) comprises a hub (40) that is equipped on its side facing toward the internal stator (20) with an axial projection (80) that is implemented for abutment against the inner ring of an adjacent rolling bearing (48), in order to enable said rolling bearing (48) to be pressed into the bearing tube (56, 58) by axial pressure on the rotor (28).
 10. The fan according to one of claims 6 to 9, wherein the rotor (28) is equipped with at least one opening (44) that enables the introduction of a tool (92) with which the holding member (96) can be brought into abutment against the outer ring of an associated rolling bearing (48).
 11. The fan according to claim 9, wherein the shaft (42) of the rotor (28) is impinged upon by a spring force (78) in order to clamp the rolling bearings (48, 50) against one another.
 12. The fan according to one of the preceding claims, wherein a closure member similar to a cover (128) or a cap (127) is provided, which member serves to close off the cavity (108).
 13. The fan according to claim 12, wherein a cover (126) is provided as a closure member, which cover is connected by a weld join to an edge (109) of the housing part that serves for reception of the electrical components (112).
 14. The fan according to claim 13, wherein the weld join is produced by laser welding.
 15. The fan according to claim 13, wherein the weld join is produced by ultrasonic welding.
 16. The fan according to claim 12, wherein the closure member (126; 127) is connected by an adhesive join to the housing part that serves for reception of the electrical components (112).
 17. The fan according to claim 12, wherein the closure member (126; 127) is connected by a mechanical seal connection to the housing part that serves for reception of the electrical components (112).
 18. The fan according to one of the preceding claims, wherein the plastic coating (56, 58) is produced from a polyamide.
 19. The fan according to one of claims 1 to 17, wherein the plastic coating is produced from PBT.
 20. The fan according to claim 18 or 19, wherein the plastic coating is produced from a fiber-reinforced plastic.
 21. The fan according to one of the preceding claims, wherein the plastic coating (56, 58) at least partly covers the central opening (149) of the stator lamination stack (64).
 22. The fan according to one of the preceding claims, wherein the plastic coating is implemented integrally with the fan housing (24) of the fan.
 23. The fan according to one of the preceding claims, wherein the plastic coating forms at least in part an electrical insulator (62) for that part of the stator lamination stack (64) which adjoins the magnetically effective air gap (99).
 24. The fan according to one of the preceding claims, wherein the winding arrangement (66; 164, 166, 168, 170) is equipped with electrical connector elements (106) which project out of the plastic casing of the internal stator (20), in particular in a direction toward the cavity (108) that is implemented on the side of the stator lamination stack (64) facing away from the rotor (28).
 25. The fan according to claim 1, wherein the bearing tube has a first end, adjacent to said rotor (28) and a second, closed end (70) remote from the rotor (28).
 26. The fan according to claim 25, wherein the bearing tube (56, 58) is formed, at its rotor-adjacent end, with a collar (60), in which is secured a holding member (96) that retains a bearing element (48) in the bearing tube (56, 58).
 27. The fan according to claim 26, wherein the holding member (96) has an edge (98) that points toward the rotor (28) and is in engagement with the collar (60) of the bearing tube (56, 58).
 28. The fan according to claim 26, wherein two rolling bearings (48, 50) are arranged at a distance from one another in the bearing tube (56, 58) as bearing elements, namely a first rolling bearing (48) mounted at the rotor-adjacent end of the bearing tube, and a second rolling bearing (50) mounted at the rotor-remote end of the bearing tube, and wherein an outer ring of said second rolling bearing (50) engages end face of a shoulder (92) formed in the bearing tube (56, 58), and said outer ring is braced with its other side, via a spacing member (52), against an oppositely located shoulder of the outer ring of the first rolling bearing (48), which outer ring is, in turn, retained in the bearing tube by said holding member (96).
 29. The fan according to claim 1, wherein the rotor (28) comprises a hub (40) that is equipped on its side facing toward the internal stator (20) with an axial projection (80) that is configured for abutment against the inner ring of an adjacent rolling bearing (48), in order to enable said rolling bearing (48) to be pressed into the bearing tube (56, 58) by axial pressure on the rotor (28).
 30. The fan according to claim 26, wherein the rotor (28) is formed a plurality of openings (44) which enable the introduction of a tool (92), with which the holding member (96) can be brought into abutment against the outer ring of an adjacent rolling bearing (48).
 31. The fan according to claim 29, further comprising a spring (78) coaxial with the shaft (42) of the rotor (28) and serving to apply a spring force, in order to urge the rolling bearings (48, 50) toward one another.
 32. The fan according to claim 1, further comprising a cover (127, 128) which serves to close off the cavity (108) for electrical components (112).
 33. The fan according to claim 32, wherein the closure member (126; 127) is connected by an adhesive join to a housing part that serves for reception of electrical components (112) of the motor.
 34. The fan according to claim 12, wherein the closure member (126; 127) is connected by a mechanical seal connection to a housing part that serves for reception of the electrical components (112).
 35. The fan according to claim 1, wherein said plastic coating (56, 58) is composed of a polyamide material.
 36. The fan according to claim 1, wherein the plastic coating is composed of a PBT plastic material.
 37. The fan according to claim 1, wherein the plastic coating is composed of a fiber-reinforced plastic.
 38. The fan according to claim 1, wherein the plastic coating (56, 58) at least partly covers a central opening (149) of the stator lamination stack (64).
 39. The fan according to claim 1, wherein the plastic coating forms, at least in part, an electrical insulator (62) for a part of the stator lamination stack (64) which adjoins a magnetically effective air gap (99) of the motor.
 40. The fan according to claim 1, wherein the winding arrangement (66; 164, 166, 168, 170) further comprises electrical connector elements (106) which project out of the plastic casing of the internal stator (20), in a direction toward a cavity (108) that is formed on a side of the stator lamination stack (64) facing away from the rotor (28). 